Grout member for modular flooring assemblies

ABSTRACT

Provided is a grout member for a modular floor. The grout member includes a core having a wedge shape, wherein the core consists of a horizontal strut interconnecting two vertical supports. A flange extends from each vertical support to position and secure the grout member in position The core supports a surface section which is oriented toward the user. The modular floor is as assembled by interconnecting modular flooring assemblies that include a flooring component, such as tile, wood or other materials commonly used in flooring applications, and subsequently inserted grout members in the gaps formed by the components

This application is a continuation-in-part of PCT/JUS06/38379 filed Oct.3, 2006, which claims the benefit of U.S. patent application Ser. No.11/432,873 filed May 12, 2006, which claims the benefit of U.S.Provisional Application No. 60/723,578 filed Oct. 4, 2005 and to U.S.Provisional Application No. 60/733,686 filed Nov. 4, 2005. The aboveidentified applications are each hereby incorporated by reference.

FIELD OF THE INVENTION

The present invention relates to a grout member for a modular flooringassembly. More particularly, the present invention relates to areplaceable, non-bonded grout member retained in position, throughfunctional forces, between two modular floor components.

BACKGROUND

Installing a conventional tile floor is a complicated procedurerequiring expertise and craftsmanship The process, which typicallyinvolves the use of “fill-in” grout, may require several hours or daysof drying time, during which time the floor must not be used. Many ofthe modular flooring assemblies disclosed in the prior art have not beenfully successful, due at least in part to a failure to provide a robust,flexible, serviceable grout component. As such, some prior art modularflooring systems allow tiles to shift or migrate resulting inunacceptable appearance and performance, as well as a cracking andseparation of the grout from the flooring components (tiles, wood,marble slabs, etc.).

In some instances, attempts have been made to correct for the problemsinherent with conventional grout approaches by incorporating in themodular flooring assembly a grout member or component that replaces orsupplements traditional fill-in grout. While the concept of a groutmember that can be inserted as a unit (and presumably removed ifdesired) is not new, existing solutions do not adequately address suchproblems as: securing the grout member between flooring components;centering the grout member; and accounting, via the grout member, forthe inevitable variances in gap widths that exist between two or moreassembled flooring components. Fox example, in U.S. patent applicationSer. No. 10/752,591 to Pepa, “Paving System for Floor Tiles” (hereinafter “Pepa”), a number of various grout member solutions are disclosed.In each instance, the problems identified above are not resolved. Morespecifically, while Pepa discloses a grout member that may be insertedin the gap between tiles, assembly often requires the grout be insertedinto a slot that is integral to one of two intersecting flooringcomponents lying the grout to the flooring component in this mannerinvariably results in movement of the grout. The grout moves as theflooring component moves, and prevents the grout from being properlycentered between tiles. Further, the solutions proposed in Pepa andothers do not adequately account for variances in gap widths betweenadjoining components/tiles. Stated differently, existing grout systemsare typically singular in size (width), and cannot easily or securelyfit into gaps of varying width. While the grout solutions of the priorart may be slightly compressed and “stuffed” into a gap which wouldotherwise be too small, this “stop gap” approach does not addressexpansion and contraction depending on the gap width.

Other grout solutions, that do not necessarily tie the grout member to aflooring component, still fall short of expectations and needs. Certainprior art systems have “sealing lips” or “beads” to help prevent theleakage of moisture and/or adhesives into the flooring substrate. Thesedesigns, however, do not provide adequate flexibility andexpansion/compression to allow for gap width variations. Thereforemoisture contamination and unwanted adhesion are still a possibilityLikewise, current systems do not provide a reliable means to secure thegrout member in the gap through spring-like or functional forces.

As such, there is a need for a flexible, removable grout member thatovercomes the limitations outlined above

SUMMARY

The methods and systems herein disclosed advance the art and overcomeproblems articulated above by providing a modular grout member that issufficiently flexible yet sturdy; a grout member that can easily fitinto gaps of varying widths while remaining centered to present anattractive and functional interstitial seal.

In particular, and by way of example only, according to an embodiment,provided is a grout member, including: a core having a horizontal strutinterconnecting a first vertical support and a second vertical support;a surface section interfaced with the horizontal strut; a first flangeextending outward from the first vertical support; and a second flangeextending outward from the second vertical support, wherein the firstflange and the second flange each interface with a corresponding modularflooring component to secure the grout member in position.

In yet another embodiment, provided is a grout member, including: awedge shaped core having a horizontal strut interconnecting a firstvertical support and a second vertical support; a surface sectioninterfaced with the horizontal strut; a first malleable, resilientlydeformable flange extending outward from the first vertical support; anda second malleable, resiliently deformable flange extending outward fromthe second vertical support, wherein each of the core, the malleable,resiliently deformable flanges, and the surface section ate formed froma different material.

In still yet another embodiment, provided is a method of sealing, withremovable grout, a modular floor assembly, including: determining apattern of required extended and truncated, removable grout members;cutting each removable grout member according to the pattern; inserting,in a first gap formed by at least four modular floor components, anextended, removable grout member; inserting, in a second gap formed bythe at least four modular floor components, a first truncated, removablegrout member; inserting in the second gap a second truncated, removablegrout member; and verifying a press fit of each inserted extended andtruncated, removable grout member.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a grout member, according to anembodiment;

FIG. 2 is a cross-sectional view of a grout member, according to anembodiment;

FIG. 3 is a cross-sectional view of a grout member positioned betweenmodular flooring components, according to an embodiment.

FIG. 4 is a cross-sectional view of a grout member positioned betweenmodular flooring components, according to an embodiment;

FIG. 5 is a cross-sectional view of a grout member having extendedflaps, positioned between modular flooring components, according to anembodiment;

FIG. 6 is a cross-sectional view of a grout member having extendedflaps, positioned between modular flooring components, according to anembodiment;

FIG. 7 is a cross-sectional view of a grout member having flangespositioned at a base of a each vertical support, according to anembodiment;

FIG. 8 is a cross-sectional view of a grout member positioned betweenmodular flooring components, according to an embodiment;

FIG. 9 is a perspective view of a grout member positioned betweenmodular flooring components, according to an embodiment; and

FIG. 10 is a perspective view of modular flooring components integratedwith grout members, according to an embodiment.

DETAILED DESCRIPTION

The present disclosure relates to a grout member or assembly for amodular floor/modular flooring assembly. The grout member is intended tofit or be installed between two adjacent floor assembly components, suchas a tile, tray, frame, etc. During the installation process, the groutmember is pressed into a channel between interconnected modular flooringassemblies. After installation, the grout member resembles traditionalfill-in grout that is spread into the grooves between adjacent tiles.The grout member is positioned such that side members or flanges extendfrom a core to contact a surface of the corresponding floor assemblycomponent The grout member may be filly formed during fabrication, maybe manufactured from one or more materials, and is supplied to consumersready for installation.

Of note, as detailed in U.S. patent application Ser. No. 11/432,873, themodular flooring assembly may comprise a tray substrate and a floorcomponent. The floor component may comprise tile, stone, marble, wood,or other conventional flooring materials. The floor component could be aceramic or porcelain tile, a natural stone product like marble orgranite, or could be a wooden product. In at least one embodiment, floortile systems may also incorporate the modular grout member disclosedherein. Each tray substrate typically includes connecting members, suchas tabs, which allow tray substrates to interlock using tabs from twoadjacent trays. The fully assembled modular floor, complete with thegrout member of the present application, provides the appearance of aconventional floor.

Importantly, the modular floor may be assembled by individuals, who maylack the training and expertise to install a conventional floor. Also,the modular floor may be quickly disassembled without damaging the subfloor; as the grout member and the modular floor are not typicallyattached to the sub floor by adhesives, grout compounds, or otherfastening means. Further, the grout member and the modular floor may beinstalled over an existing sub floor without the installation of aconcrete backer board, which is commonly used in ceramic tileinstallation.

The present invention, using a grout member that is not permanentlyintegrated with a tray or tile, offers certain advantages in assemblyand disassembly. Further, the consumer may choose from among manydifferent colored grout members. A damaged grout member may be easilyreplaced, and the grout member may also be changed to reflect differentdecorating tastes.

The modular flooring assemblies associated with the present inventionmay be in any number of sizes and shapes well known in the art, toinclude 6-inch, 6½-inch, 12-inch, 13-inch and 18-inch embodiments. Theymay have a square or rectangular shape. Further, combinations offlooring assemblies/tiles may be used, such as the 6-inch and 12-inchmodular flooring assemblies, to provide a unique appearance. The presentinvention may be modified to compliment these combinations of differentsized modular flooring assemblies. For each design of flooring assembly,the grout member of the present disclosure may be tailored in length toprecisely align with the floor components.

Referring now to FIGS. 1 and 2, a perspective and a cross-sectional viewof a grout member are presented. As shown in the figures, the groutmember 100 may include a substantially horizontal section or strut 102which interfaces with and joins two substantially vertical supports, 104and 106 respectively. The vertical supports 104, 106 may intersect thehorizontal strut 102 at any angle desired, typically at an angle in therange of 45° to 90° (i.e. normal to the horizontal strut 102.). In atleast one embodiment of the present application, as represented in FIGS.1 and 2, the angle formed by the vertical supports 104, 106 and thehorizontal strut 102 is much closer to 90° than to 45°, on the order of75°-85°.

Collectively, horizontal strut 102, and vertical supports 104, 106comprise the core 108 of grout member 100. As shown, core 108 may have a“wedge-shaped” design that assists in holding grout member 100 in placebetween the tray substrates, tiles, or modular flooring assemblies. Inparticular, as the grout member 100 is installed between modularflooring components or assemblies, the “wedge” formed by the twovertical supports 104, 106 is compressed. This compression and theresulting opposite force supplied by the “wedge” assists in stabilizingand retaining the grout member 100 subsequent to its installationbetween the tray substrates, tiles, etc. The core 108 is generallyformed as the hardest portion of the grout member 100. For example, inone embodiment a polypropylene may be used to form the core 108.

A surface section 110 is positioned atop of the core 108. Morespecifically, surface section 110 interfaces with and is secured tohorizontal strut 102. In one embodiment, surface section 110 may beformed on the core 108 during an extrusion process. When an individualis standing on a modular floor incorporating grout member 100, and themember 100 is fully installed into a tray substrate or a modular floor,surface section 110 is the visible portion of the member 100.

The surface section 110 may be manufactured from a polypropylene thermalelastomer (TPE) such as SANTOPRENE®. In one or more embodiments, theelastomer of surface section 110 may contain a glass filled. The glasscontent may be approximately 3 percent to approximately 10 percent. Theglass filler simulates the feel and appearance of a sanded grout, whichis a desirable cosmetic feature. The glass filler further assists instabilizing the temperature changes in the surface section 110elastomer, which is an important functional feature since it reduces theexpansion and contraction of the elastomer due to temperaturefluctuations. Further, the elastomer may be manufactured in a variety ofcolors, and integrated with a variety of glass fillers, to matchconsumer choices in decorating.

In at least one embodiment, the surface section 110 may be made from athermal plastic rubber or other resiliently deformable, compressible,pliable, malleable sealing material designed to fit between the tiles ortray substrates. The surface section 110 may include fluted edges 112and 114 that seal against a tile and assist the grout member 100 inproviding the finished appearance of conventional fill-in grout.

Still referring to FIGS. 1 and 2, flanges 116 and 118 extend generallyoutward from each vertical support 104, 106, respectively. As shown inFIG. 2, flange 116 extends outward from vertical support 104. Similarly,flange 118 extends outward from vertical support 106. The flanges 116,118 may generally taper in width towards a tip, 120 and 122respectively. However, it can be appreciated that the presentapplication also anticipates and discloses an extended flange or flangesthat are not tapered, such as those depicted in FIG. 7 (flanges 700 and702). As illustrated in greater detail in FIG. 2, the flanges 116, 118form an angle “α” in the range of approximately 30° to approximately 70°relative to the vertical supports 104, 106, when uninstalled. Asdiscussed in greater detail below, the flanges 116, 118 are formed of amalleable, resiliently deformable material and may bend and flex,thereby reducing the angle “α” and, in this manner, assist in holdingthe grout member 100 in position.

The grout member 100, which includes the surface section 110, core 108,and flanges 116, 118, may be formed from co-extrusion processes. Each ofthe core 108, the surface section 110, and the flanges 116, 118 may beco-extruded using three different materials exhibiting physicalproperties directed to the particular function of each element orcomponent. For example, as represented in FIG. 2, the core 108 may beformed from a first material 124, the flanges 116, 118 may be formedfrom a second material 126, and the surface section 110 may be formedfrom a third material, 128. The first material 124 forming the core 108may be harder than the second 126 and third 128 materials, as the core108 forms a supporting structure. The co-extrusion process reducesmanufacturing costs and provides a uniform product.

In at least one embodiment of the present disclosure, grout member 100forms a generally straight structure with a generally uniformcross-section throughout its entire length. The grout member 100 may beproduced in any length practical and economical; however, standardlengths may include 8 foot lengths and 12 inch lengths, which aresuitable for installing with 12 inch by 12 inch tiles. Since 8 footlengths may be utilized, installation time is reduced as many of thegrout lines in a first direction may be installed with the 8 footlengths of the grout member 100, while the 12 inch lengths may beinstalled in a second, opposite direction. As there are fewer pieces toinstall as compared to other embodiments, installation labor times maybe reduced.

The grout member 100 may be used with any size tile. Generally, as notedabove, grout member 100 will be supplied to the customer in two lengths,an extended length, such as several feet to approximately 8 to 12 feet,and a second, truncated, length generally corresponding to the length ofthe tile, which may be 6-inch, 12-inch, 13-inch, 18 inch, etc. By usinggrout members 100 with the extended lengths, the finished modular floorwill have less grout seams (points where two sections of groutintersect) and installation is easier, since there are less extrudedgrout sections to install. The extended lengths of grout member 100 mayalso be easily cut to fit with snips, heavy shears, or a light saw.

Referring now to FIGS. 3 and 4, a unique feature of the presentdisclosure is highlighted As noted above, flanges 116, 118 may bend andflex, thus creating a “spring action” to assist in positioning andholding the grout member 100 between two components of a modular floor(tray, flame, tile, etc.). The mechanical consequences of this elementof the invention are that differences or discrepancies in the gapbetween modular floor components can be accommodated and accounted forwhile still providing a finished grout look and seal. More specifically,if the gap “b” (FIG. 4) between two trays 400, 402 and tiles 404,406 issmaller than gap “a” (FIG. 3) between similar trays 300, 302, and tiles304, 306 in a given modular floor assembly, flanges 116 and 118 may bendand flex (in the case of gap b”), or fully extend (in the case of gap“a”), thereby allowing the grout member 100 to be securely centered ineach instance. Concurrently, the surface section 110 may be compressedas well to fit within the gap presented. Stated differently, groutmember 100 can account, in large part, for the mechanical tolerancesthat inevitably build-up during the assembly, of any modular system,despite the best designs and manufacturing techniques. By virtue of“flexible” flanges and not being tied to one Or the other modularcomponents (e g. 300, 302, 400 or 402), grout member 100 is free to“float” and always remain centered in position. Of note, this same “flexand bend” capability of flanges 116, 118 helps to ensure that a tightpress fit is achieved between grout member 100 and the two modular floorcomponents, even if the floor component surfaces with which grout member100 interfaces are not truly parallel; and (b) a greater surface area ofthe flange, e.g., flange 116, contacts a surface of the modular floorassembly, e.g. tray 400, thereby providing greater frictional(mechanical) forces to hold the grout member 100 in place.

Importantly, grout member 100 provides several sealing surfaces to sealthe grout-modular floor assembly and prevent moisture or fluids fromentering the tray substrate or the modular floor. As can be appreciatedby referring, for example, to FIGS. 3 and 5, the surface section 110FIG. 3) or 500 (FIG. 5) may form a seal pressing against the tile, e.g.tile 304 in FIG. 3 and tile 502 in FIG. 57 to form a moisture, adhesive,and dust barrier. Likewise the flange combinations (e.g. 116 and 118 inFIG. 3/506 and 508 in FIG. 5) also form a seal by pressing against atile or tray, e.g. tray 510 in FIG. 5.

Referring now to FIGS. 5 and 6, an alternate embodiment of the presentdisclosure is depicted, wherein the surface section 500 may includeextended flaps (512, 514) on either side of the surface section 500. Asshown, if the gap between modular floor components, e.g. trays 510 and516, is sufficiently wide, the extended flaps 512, 514 will meet flushwith the edge of the tile 502 or 518. If, however, as shown in FIG. 6the gap varies and is occasionally somewhat smaller than typicallyencountered, as if often the case with modular floors, the extendedflaps 512, 514 may extend over the top surfaces 520, 522 of the tiles502, 518, thereby adequately sealing the gap while providing a finishedlook to the entire grout—floor assembly.

Referring once again briefly to FIG. 7, yet another embodiment of thepresent disclosure is presented. As shown, flanges 700 and 702 arepositioned lower relative to the length of the vertical supports, 704and 706 respectively, and the position of the surface section 708.Stated differently, flange 700 extends outward from a base of support704 while flange 702 similarly extends outward from a base of support706. As such, the flanges 700 and 702 may be somewhat longer in lengththan those shown in the other embodiments. The advantage to thisembodiment is that greater flexibility may be designed into the flanges700, 702, which in turn typically yields a greater flange-to-modularfloor interlace surface when the grout member 710 is placed intoposition, similar to FIGS. 4 and 6.

In FIG. 8, a grout member 800 is fully installed into the gap or channel802 formed when two modular floor assemblies, e.g. assemblies 804 and806, are interlocked. As shown in FIG. 8, the interlocking tabs 808 and810 form a strong, semirigid base upon which the bottom tips 812, 814 ofvertical supports 816, 818 press down. This positioning provides astabilizing foundation for the grout member 800. The foundation providedby the core 820 and the two vertical supports 816, 818 pressing on thebase formed by the tabs 808, 810, withstands the substantial weight ofindividuals walking on the fully assembled modular floor, as well as theweight of furniture, appliances, etc. By supporting the core 820 and thevertical supports 816, 818, in the manner depicted in FIG. 8, the groutmember 800 has a solid feel that does not feel spongy or soft to thetouch, i.e., the grout member 800 feels similar to a traditional fill-ingrout product. The two vertical supports 816, 818 provide a firmpedestal for the grout member 800 and assist in securing the position ofthe grout member 800. In at least one embodiment, as shown in FIG, 8 andelsewhere, the core 820 has a hollow region between the two verticalsupports 816, 818. The practical result of combining a semi-hollow corewith well supported vertical supports is a reduced material cost whilemaintaining strength and structural integrity.

Considering for a moment FIG. 9, yet another implementation of thepresent disclosure is presented. In many instances, the tile or otherflooring used in a modular floor design may be beveled. For example, inFIG. 9, tile 900 has a beveled edge 902 oriented and sloping generallytoward the grout member 904. In this instance, the top of grout member904 may not be positioned flush with the top surface of the tile 900,but may instead lest lower within the gap 906. Nonetheless, the surfacesection 908 of member 904 fits flush against the tile 900 side surface,providing the necessary seal between flooring and grout. In at least oneembodiment employing a beveled tile design, fill-in grout of the typewell known in the art may be placed above the surface section 908 tofully close out the gap 906. When fill-in grout is employed, groutmember 904 serves to properly maintain the size and integrity of the gap906, support the hardened fill-in grout, and minimize the amount offill-in grout required to fill the gap 906.

Referring now to FIG. 10, a modular floor assembly 1000, includinginterconnected modular flooring trays 1002, 1004, 1006 and 1008 isdisclosed. The trays may be any tray or frame-type device used to secureflooring materials, to include the frames with tabs disclosed andclaimed in U.S. patent application Ser. No. 11/432,873 filed May 12,2006. For simplicity sake, a single tile, 1010 is shown positionedwithin tray 1008, however, it can be appreciated that all four trays1002-1008 would typically contain a tile or other flooring component(wood, marble, etc.). For exemplary purposes, a single, extended groutmember 1012 and two truncated grout members 1014 ate 1016 are showninstalled in a finished position. After the modular flooring assemblies(trays) are interconnected, a pattern is established and the requiredgrout lengths defined. Accordingly, grout members (e.g. member 1012) arecut to length. A grout member (e.g. 1012) is installed by pressing thegrout member in the gap between the modular flooring assemblies. Nospecial tools are required. Extended and truncated grout members (e.g.1012 and 1014) are installed in a repeating pattern until the entirefloor assembly is grouted. A grout member of the present application isa fabricated structure that does not undergo a drying process or phasechange during its installation. Unlike a traditional fill-in grout, thegrout member is not a paste or compound that is spread between themodular flooring components, therefore installation and clean up aresimplified.

As the grout members, e.g. member 1012, are installed between modularflooring components, the flanges, e.g. flange 116 in FIG. 2 and 1018 inFIG. 10, are forced upward, thus providing a spinning-action to hold thegrout member e.g. member 1012 in position. Importantly, in at least oneembodiment as discussed above, the flanges (e.g. flange 1018) arepushing outward against an edge of the flooring component (e.g. tray1008) while the wedge shape formed by the two vertical supports, e.g.support 1020, is pressing on a top surface of tabs attached to the trays1002-1008. This action of anchoring the grout member 1012 against thesetwo different surfaces, namely the edge of tray 1008 and the tabsattached thereon (not shown), provides for the secure installation ofthe grout member, e.g. member 1012 At the completion of theinstallation, the press fit of all grout members is verified. Despitethe wedge action, the grout member 1012 may be removed from the modularfloor after it is installed by a firm pulling action.

The flanges, e g, flange 1018, preferably extend the entire length ofthe grout member 1012, although a grout member with an intermittent oxdiscontinuous flange may also be used. The dimensions of certainembodiments of an extruded grout member (e.g. 1012, 1014, 1016) mayinclude: (a) a surface section having a thickness of approximately 0.05inches to approximately 0.09 inches and a width of approximately 0.2inches to approximately 0.3 inches; (b) a core, including the twovertical supports, having a thickness of approximately 0.02 inches toapproximately 0.05 inches; and (c) flanges having a width ofapproximately 0.1 inches to approximately 0.3 inches. These dimensionsdescribed are suitable for many applications of modular flooring;however, the dimensions may be altered by one of ordinary skill in theart practicing the invention as required for their particular tilingapplication.

Changes may be made in the above methods, devices and structures withoutdeparting from the scope hereof. It should thus be noted that the mattercontained in the above description and/or shown in the accompanyingdrawings should be interpreted as illustrative and not in a limitingsense. The following claims are intended to cover all generic andspecific features described herein, as well as all statements of thescope of the present method, device and structure, which, as a matter oflanguage, might be said to fall therebetween.

1. A grout member, comprising: a core having a horizontal strutinterconnecting a first vertical support and a second vertical support;a surface section interfaced with the horizontal strut; a first flangeextending outward from the first vertical support; and a second flangeextending outward from the second vertical support wherein the firstflange and the second flange each interface with a corresponding modularflooring component to secure the grout member in position.
 2. The groutmember of claim 1, wherein the first flange and the second flange areresiliently deformable.
 3. The grout member of claim 1, wherein thesurface section is a polypropylene thermal elastomer.
 4. The groutmember of claim 3, wherein the surface section is a polypropylenethermal elastomer having a glass content in the range of 3 to 10percent.
 5. The grout member of claim 1, wherein the core is a firstmaterial, the first and the second flanges are a second material, andthe surface section is a third material.
 6. The grout member of claim 5,wherein the hardness of the core material is greater than the hardnessof the flange material and the surface section material.
 7. The groutmember of claim 1, wherein the first flange extends outward from a baseof the first vertical support, and further wherein the second flangeextends outward from a base of the second vertical support.
 8. The groutmember of claim 1, wherein the surface section comprises: a firstextended flap; and a second extended flap.
 9. The grout member of claim1, wherein the first flange and the second flange extend continuouslyalong an entire length of the grout member.
 10. The grout member ofclaim 1, wherein the first flange and the second flange arediscontinuous.
 11. The grout member of claim 1, wherein the member isextruded.
 12. The grout member of claim 1, wherein the first flange andthe second flange are tapered.
 13. A grout member, comprising: a wedgeshaped core having a horizontal strut interconnecting a first verticalsupport and a second vertical support; a surface section interfaced withthe horizontal shut; a first resiliently deformable flange extendingoutward from the first vertical support; and a second resilientlydeformable flange extending outward from the second vertical supportwherein each of the core, the resiliently deformable flanges, and thesurface section are formed from a different material.
 14. The grout ofclaim 13, wherein the core is made of a first material that is harderthan both a second material forming the flanges and a third materialforming the surface section.
 15. A method of'sealing, with removablegrout, a modular floor assembly, comprising: determining a pattern ofrequired extended and truncated, removable grout members; cutting eachremovable grout member according to the pattern; inserting, in a firstgap formed by at least four modular floor components, an extended,removable grout member; inserting, in a second gap formed by the atleast four modular floor components, a first truncated, removable groutmember; inserting in the second gap a second truncated, removable groutmember; and verifying a press fit of each inserted extended andtruncated, removable grout member.
 16. The method of claim 15, whereinthe pattern of one extended and two truncated removable grout membersrepeats.
 17. The method of claim 15, wherein a surface section of eachof the extended and truncated grout members is a polypropylene thermalelastomer.
 18. The method of claim 17, wherein the surface section ofeach of the extended and truncated grout members is a polypropylenethermal elastomer having a glass content in the range of 3 to 10percent.
 19. The method of claim 15, wherein a core of each grout memberis a first material, a first and a second flange of each grout member isa second material, and a surface section of each grout member is a thirdmaterial.
 20. The method of claim 19, wherein the hardness of the corematerial is greater than the hardness of the flange material and thesurface section material.